Modular construction kits

ABSTRACT

A modular construction kit has a plurality of components comprising first components which consist of substantially straight elements ( 1 - 3 ), second components ( 4 - 6 ) which are curved and subtend an angle of approximately 12°, third components ( 7 - 9 ) which are curved and subtend an angle of approximately 6°, the radius of the curved second components being approximately 604 mm and the radius of the curved third components being approximately 440 mm, and fourth components ( 10 - 12 ) which consist of corner elements. Each component is provided with connecting means ( 16 - 30 ) at its ends which enable the component to be connected to other components at one or both ends. The modular construction kit may include a plurality of fifth components which comprise end elements ( 13 - 15 ) which have only one connecting means ( 16 - 30 ) enabling an end element to be connected to one end of a first, second, third or fourth component.

This invention relates to modular construction kits and is particularly concerned with a modular construction kit which can be used to construct a plurality of toys or furniture having a wide variety of shapes and configurations.

According to the invention there is provided a component for a modular construction kit, according to claim 1. Preferred features are set out in the sub-claims. Another aspect of the invention provides a modular construction kit having a plurality of components comprising first components which consist of substantially straight elements, second components which are curved and subtend a first angle, third components which are curved and subtend a second angle which is approximately half of the first angle and fourth components which consist of corner elements, each component being provided with connecting means at its ends which enable the component to be connected to other components at one or both ends.

Preferably, the curved second components subtend an angle of approximately 12° and the curved third components subtend an angle of approximately 6°. The radius of curvature of the second components is desirably approximately 604 mm and the radius of curvature of the third components is desirably approximately 440 mm. The modular construction kit according to the invention may also include a plurality of fifth components which comprise end elements having only one connecting means enabling an end element to be connected to one end of a first, second, third or fourth component.

Preferably, each component is available in three widths so that the first components can consist of wide, medium and narrow straight elements, the second and third components can consist of wide, medium and narrow curved elements and the fourth components can consist of wide, medium and narrow corner elements.

Likewise, the fifth components may be available in three widths and consist of wide, medium and narrow end elements.

The combined width of the medium and narrow components is desirably substantially equal to the width of the wide components.

According to a preferred embodiment of the invention, each of the components comprises a span profile which is the widest of the components and has connecting means at each side and two cap elements which are the medium and narrow components and have connecting means at only one side.

The wide components or span profiles desirably have a width of approximately 47 mm, the medium components desirably have a width of approximately 29 mm and the narrow components desirably have a width of approximately 18 mm.

Preferably, the connecting means comprise a wedge shaped shaft and a wedge shaped hole, the shaft at one end of each component being adapted to be inserted into the hole at an end of another component which is adapted to receive the shaft of said one component and the shaft at the said end of the other component being adapted to be inserted into the hole at the said one end of the said one component which is adapted to receive the shaft.

Desirably, the span profiles have two shafts and two holes at each end except for the fifth components which have shafts and holes at only one end.

Preferably, the shaft of each connecting means is attached to an end of a component by a neck.

The wedge shaped holes are preferably provided with latches for engaging with bars in the shafts to lock connected components together.

A key may be provided which is adapted to engage with the latches to unlock connected components to allow them to be separated.

Each corner component preferably has two faces, each provided with connecting means, the two faces desirably extending at an angle of approximately 96° to each other.

The components of the modular construction kit according to the invention are preferably made of a plastics, preferably durable plastics, material.

According to a preferred embodiment of the invention, all of the five 47 mm wide span profiles have identical interlocking ends, each of which is made up of a wedge shaped shaft, 29 mm on one side and 18 mm on the other, and a wedge shaped hole 29 mm and 18 mm that corresponds to the wedge shaped shaft. Each wedge shaped hole has a locking mechanism that corresponds to bars in each shaft.

The 29 mm wedge shaft can slide into the corresponding 29 mm hole on any two span profiles where two locks hook onto the corresponding bars in a tight fitting joint, which cannot be separated without a special key. When connected face-to-face the span profiles are offset by 18 mm on either side revealing the other end of the wedge shaft and a corresponding 18 mm wedge hole.

Any span profile can then be attached to the assembly by sliding the corresponding 18 mm hole with the protruding 18 mm shaft and locked in a similar tight fitting wedge lock. By this process the assembly can be made as wide as the user chooses in increments of 47 mm.

Alternatively a corresponding 18 mm wide cap element which has a corresponding 18 mm wedge shaft and 18 mm wedge hole, can be used to cap the side of the assembly using the same tight fitting wedge lock mechanism.

The span profiles can also be connected back-to-back where the 18 mm wedge shaft can slide into the corresponding 18 mm hole on any two span profiles offsetting the joint by 29 mm revealing the 29 mm shaft and 29 mm in which the 29 mm wide cap element can be connected with the same tight fitting wedge double lock mechanism.

The invention will now be described in detail, by way of example, with reference to the drawings, in which:

FIG. 1 is a perspective view of the first components of the invention;

FIG. 2 is a perspective view of the second components of the invention;

FIG. 3 is a perspective view of the third components of the invention;

FIG. 4 is a perspective view of the fourth components of the invention;

FIG. 5 is a perspective view of the fifth components of the invention;

FIG. 6 is a plan view, section and side views showing the joint detail of the span components in FIGS. 1, 2, 3, 4, & 5;

FIG. 7 is a plan view, section and side views showing the joint detail of the wide cap components in FIGS. 1, 2, 3, 4, & 5;

FIG. 8 is a plan view, section and side views showing the joint detail of the narrow cap components in FIGS. 1, 2, 3, 4, & 5;

FIG. 9 is a perspective view of the components in FIG. 2 illustrating the manner of assembly;

FIG. 10 is a perspective view of the components shown in FIG. 9, showing four possible variations of assembly;

FIG. 11 are sections of the joints showing the assembly of two span and two narrow cap components as shown in FIG. 9;

FIG. 12 are sections of the joints showing the assembly of four span and two narrow cap components;

FIG. 13 is a perspective view of the assembly of a sledge using the components illustrated in FIGS. 1, 2, 3, 4, & 5;

FIG. 14 is a plan view of a key component;

FIG. 15 is a section of the key component inserted to unlock the wide cap element;

FIG. 16 is a section of the key component inserted to unlock the narrow cap element;

FIG. 17 is a section of the key component inserted to unlock face-to-face span components;

FIG. 18 is a section of the key component inserted to unlock back-to-back span components;

FIG. 19 is a perspective view of an assembled chair;

FIG. 20 is a perspective view of an assembled table;

FIG. 21 is a perspective view of an assembled rocking horse;

FIG. 22 is a perspective view of an assembled see saw;

FIG. 23 is a perspective view of an assembled high chair;

FIG. 24 is a perspective view of an assembled dining chair;

FIG. 25 is a perspective view of an assembled slide; and

FIG. 26 is a perspective view of an assembled poolside bed or sun lounger.

In the drawings, like parts are denoted by like reference numerals.

Reference will first be made to FIGS. 1, 2, 3, 4 & 5 of the drawings in which the modular construction kit according to the invention comprises five components of different lengths and angles each with a span and two cap elements.

The components 1, 2 and 3 in FIG. 1 are the span and wide and narrow cap elements respectively of the first component, which are flat in shape and the longest of all of the five components. Similarly the second components 4, 5 and 6 in FIG. 2 are the span and wide and narrow cap elements respectively of the second component, which are curved in shape and subtend an angle of 12° with a centre line radius of curvature of 604 mm. FIG. 3 shows the third components 7, 8 and 9 which are the span, wide and narrow cap elements respectively, which are also curved in shape but in this case subtend an angle of 6° and are shorter than the components in FIG. 2 having a centre line radius of curvature of 440 mm. The fourth components in FIG. 4 are angled in profile, 96° between the ends and comprise a span element 10, a wide cap element 11 and a narrow cap element 12. The fifth components span 13, wide cap 14 and narrow cap 15 elements in FIG. 5 have only one connecting end.

Each of the span components 1, 4, 7, 10, & 13 is 47 mm wide and has identical end details, shown in plan, section and side views in FIG. 6. The interconnecting ends of the span components comprise a wedge shaped shaft 19-20 that is connected to the body of the component by a neck 16, next to openings 17 and 18. A wedge shaped hole 21 corresponds to the dimensions of the shaft 19, and passes through the body of the component. Similarly a wedge shaped hole 22 on the opposite side corresponds to the dimensions of the shaft 20.

Each of the wide cap elements 2, 5, 8, 11 & 14, which is 29 mm wide, also has identical end details shown in plan, section and side views in FIG. 7. The connecting ends of the cap elements comprise a wedge shaped shaft 25 connected to the body by a neck 23 and corresponding to the dimensions of a wedge shaped hole 26.

Similarly, each of the narrow cap elements 3, 6, 9, 12 & 15, which is 18 mm wide, also has identical end details shown in plan, section and side views in FIG. 8. The connecting ends of the cap elements comprise a wedge shaped shaft 29 connected to the body by a neck 27 and corresponding to the dimensions of a wedge shaped hole 30.

FIG. 6 shows the connecting ends of the span components that are 47 mm wide. There are two ways to connect the span components together.

The first connection is by rotating another span component anti-clockwise to where the wedge shape of the shaft 19 fits into the corresponding wedge shaped hole 21 which is 29 mm deep, and the neck 16 slides into an opening 17. A latch 32 in the hole 21 engages with a bar 34 on the shaft 19 to lock the two span components face-to-face.

The second connection is by rotating another span component clockwise to where the wedge shape of the shaft 20 fits into the corresponding wedge shaped hole 22 which is 18 mm deep. A latch 33 in the hole 22 engages with a bar 35 on the shaft 20 to lock the two span components back-to-back.

Both connection methods result in a tight fitting wedge double lock. The components are hollow as indicated by the void 37 in FIG. 6.

FIG. 7 shows the connecting ends of the wide cap elements that are 29 mm wide. The wedge shaped shaft 25, the hole 26, a bar 40, latch 39 and opening 24 are identical in shape and dimensions to 19, 21, 34, 32 & 17 of the ends of the span components respectively. This allows the cap element to fit tightly in a similar wedge lock to the corresponding span component of the same profile where shaft 24 fits into hole 21 and a neck 23 slides into opening 17, with a latch 39 engaging with the bar 34 and the latch 32 engaging with a bar 40 on the shaft 25 in a double locked tight fitting joint.

Two wide cap elements can also be connected face-to-face by rotating another cap element clockwise where shaft 25 fits into hole 26 with neck 23 sliding into opening 24 and with the latch 39 engaging with the bar 40 in a double locked tight fitting joint. The elements are hollow as indicated by the void 43 in FIG. 7.

FIG. 8 shows the connecting ends of the narrow cap elements that are 18 mm wide. The wedge shaped shaft 29, hole 30, a bar 46, lock 45 and slot 28 are identical in shape and dimensions to 20, 22, 35, 33 & 18 of the ends of the span profiles respectively. This allows the cap element to fit tightly in a similar wedge lock to the corresponding span component of the same profile where shaft 29 fits into hole 22 and a neck 27 slides into opening 18, with a latch 45 engaging with the bar 35 and the latch 33 engaging with a bar 46 on the shaft 29 in a double locked tight fitting joint.

Similarly two narrow cap elements can also be connected face-to-face by rotating another cap element clockwise where shaft 29 fits into hole 30 with neck 27 sliding into opening 28 and with the latch 45 engaging with the bar 46 in a double locked tight fitting joint. The elements are hollow as indicated by the void 49 in FIG. 8.

FIG. 9 shows the manner of assembly of two curved span components 4 and two curved narrow cap elements 6 where the shaft 19 fits into hole 21 in a wedge lock face-to-face as described above. The two narrow cap elements 6 then fit to the assembled components 4 where shaft 29 fits into hole 22 and shaft 20 fits into hole 30 also in a tight fitting wedge lock.

FIG. 10 shows the variations of the assembled curved components in FIG. 9, of two span components 4 and two narrow cap elements 6. There are four possible combinations possible at each joint as shown, down-down, down-up, up-down and up-up.

FIG. 11 shows sections of two span ends and two narrow cap ends of the assembly in FIG. 9. Shaft 29 of the narrow cap end fits into hole 22 of the span end, while shaft 20 fits in hole 30, where the latch 33 engages with the bar 46 and the latch 45 engages with the bar 35 in a double locking tight fitting wedge joint. The span ends connect to each other face-to-face with each shaft 19 fitting into each corresponding hole 21, where the latches 32 engage with the bars 34 also in a double locking tight fitting wedge joint. The narrow cap end completes the assembly in the same way as described above.

FIG. 12 shows a narrow cap end and two span ends connected where each joint is secured with a double lock by latches 32, 33 and 45 engaging with bars 34, 46 and 35 respectively. Two span ends connected face-to-face can then connect back-to-back to the span ends where shafts 20 fit into holes 22 and latches 33 engage with bars 35 in a tight fitting double lock wedge joint. To complete the assembly a narrow cap end connects to the span end as explained in FIG. 11. In this way, the assembly can connect as many span elements together as required to achieve the desired width of a toy or furniture.

FIG. 13 is a partially exploded perspective view of the assembly of a sledge. The table shows the quantities of the components used in the assembly. The width of the assembly consists of six span components and one narrow cap component. When the span components are connected together facing each other as described in FIG. 9, there is a staggered step of 18 mm with the wedge shaft 20 and corresponding hole 22 exposed on either side. This allows for the span components to be connected to each other where the wedge shaft 20 locks into the corresponding hole 22. At the sides of the assembly narrow cap elements are locked in place with the corresponding span profile components, to complete the whole assembly, with the joint assembly perpendicular to the forces of gravity, and with each joint having a double lock mechanism where the wedge shapes result in a tight fitting joint. This results in a solid assembled structure which will not come apart in use.

FIG. 14 is a plan view of a key component 50 which, when inserted into the assembled spans or cap joints, lifts the tips of the latches allowing the components to be pulled apart. Prongs 51, 52, 56 and 57 correspond in dimensions to notches 36 in the bars 34, 35 of the span component in FIG. 6, or notches 36 in the bar 40 or 46 of the wide and narrow cap end elements in FIGS. 7 and 8 respectively. Flanges 53, 54 and 58, 59, also correspond to the dimensions of keyholes 41 and 42 in the wide cap end elements and keyholes 47 and 48 in the narrow cap end elements. Beams 55 and 60 correspond to the dimensions of the openings 18 and 17 in either side of the span end elements respectively.

FIG. 15 is a section showing the key component 50 inserted into slots 41 and 42 of the wide cap and span assembly, where the prongs 51 and 52 fit into the notches in bars 40 and 34 sliding under and lifting latches 32 and 39, allowing the wide cap to be easily pulled apart from the span component.

FIG. 16 is a section showing the key component 50 inserted into slots 47 and 48 of the narrow cap and span assembly, where the prongs 56 and 57 fit into the notches in bars 46 and 35 sliding under and lifting latches 33 and 45, allowing the narrow cap element to be easily pulled apart from the span component.

FIG. 17 is a section showing the key component inserted into an assembly of two span components face-to-face. The key is inserted inside the hollow section of shaft 20 and the hole 22 where beam 55 slides inside opening 18. Prongs 51 and 52 slide into the notches in bars 34 on both sides and lift the latches 32. This allows the span components to be easily separated.

FIG. 18 is a section showing the key component 50 inserted into an assembly of two span components back-to-back. The key is inserted inside the hollow section of shaft 19 and the hole 21 where beam 60 slides inside opening 17. Prongs 56 and 57 slide into the notches in bars 35 on both sides and lift the latches 33. With the key inserted, the span components can be easily separated.

FIGS. 19, 20, 21, 22, 23, 24, 25 and 26 show examples of possible assemblies using the components shown in FIGS. 1, 2, 3, 4 and 5. These assemblies include a chair 300 mm wide in FIG. 19, a table 488 mm deep in FIG. 20, a rocking horse 253 mm wide in FIG. 21, a see-saw 206 mm wide in FIG. 22, a high chair 300 mm wide in FIG. 23, a dining chair 441 mm wide in FIG. 24, a 300 mm wide slide in FIG. 25 and a 629 mm wide poolside bed or sun lounger in FIG. 26.

The accompanying tables show the quantities of components used in each assembly. The width of the assemblies is determined by factors of the 47 mm wide span components and the choice of using either the 18 mm wide or 29 mm wide cap elements.

The components can be manufactured in various colours and the assemblies shown in FIGS. 13 and 19 to 26 could be made from components of different colours. For example, the legs of the high chair shown in FIG. 23 could be red, the back and seat could be black and the table could be white.

The invention is not restricted to the above described embodiments but variations and modifications may be made without departing from the scope of the invention. For example, the span components need not be 47 mm wide but could be wider or narrower. However, it is preferred that the combined width of the cap elements should be substantially equal to the width of the span components. Further, the invention is not restricted to the assemblies shown in FIGS. 13 and 19 to 26 of the other drawings but many other assemblies can be made from the components forming the modular construction kit according to the invention. 

1. A component for a modular construction kit, the component comprising: a first component including a substantially straight element; a second component which is curved and subtends a first angle; a third component which is curved and subtends a second angle which is approximately half of the first angle; or a fourth component which includes a corner element; the component being provided with a connecting means at its ends which enable the component to be connected to other components at one or both ends; wherein the connecting means comprises a wedge shaped shaft and a wedge shaped hole, the shaft at one end of the component being adapted to be inserted into the hole at an end of another component which is adapted to receive the shaft of said one component and the shaft at the said end of the other component being adapted to be inserted into the hole at the said one end of the said one component which is adapted to receive the shaft.
 2. The component of claim 1, wherein the wedge shaped shaft and the wedge shaped hole are situated adjacent each other at the end of the component and are oriented in the same direction.
 3. The component of claim 1, wherein an axis is defined between the ends of the component and wherein the wedge shaped shaft and wedge shaped hole that comprise the connecting means extend perpendicular to the axis.
 4. The component of claim 1, wherein the connecting means is provided on each side of the ends of the component, such that the component can be connected to another component on both sides as well as at both ends.
 5. The component of claim 4, wherein each wedge shaped shaft at each end of the component is co-axial with the wedge shaped shaft on the other side of the said end of the component and each wedge shaped hole at each end is co-axial with the wedge shaped hole on the other side of said end.
 6. The component of claim 1, wherein the shaft of each connecting means is attached to an end of the component by a neck.
 7. The component of claim 1, wherein the wedge shaped holes are provided with latches for engaging with bars in the shafts to lock connected components together.
 8. The component of claim 1, further comprising a modular construction kit including a plurality of components.
 9. The component of claim 7, wherein the modular construction kit having a plurality of components further comprises a key which is adapted to engage with the latches to unlock connected components to allow them to be separated.
 10. The modular construction kit of claim 9, wherein the key comprises two prongs arranged to disengage the latch of the wedge shaped hole of each of the two connected components at the same time.
 11. The component of claim 1, wherein the curved second components subtend an angle of approximately 12° and the curved third components subtend an angle of approximately 6°.
 12. The component of claim 1, wherein the radius of curvature of the second component is approximately 604 mm.
 13. The component of claim 1, wherein the radius of curvature of the third components is approximately 440 mm.
 14. The modular construction kit of claim 8, further including a plurality of fifth components which comprise end elements having only one connecting means enabling an end element to be connected to one end of a first, second, third, or fourth component.
 15. The modular construction kit of claim 8, wherein each of the plurality of components is provided in three widths so that the first components consist of wide, medium and narrow straight elements, the second and third components consist of wide, medium and narrow curved elements and the fourth components consist of wide, medium and narrow elements.
 16. The modular construction kit of claim 14, wherein the fifth components are available in three widths and consist of wide, medium and narrow end elements.
 17. The modular construction kit of claim 15, wherein the combined width of the medium and narrow components is substantially equal to the width of the wide components.
 18. The modular construction kit of claim 15, wherein each of the components comprises a span profile which is the widest of the components and has connecting means at each side and two cap elements which are the medium and narrow components and have connecting means at only one side.
 19. The modular construction kit of claim 18, wherein the wide elements have a width of approximately 47 mm, the medium width elements have a width of approximately 29 mm and the narrow elements have a width of approximately 18 mm.
 20. The modular construction kit of claim 18, wherein the connecting means of the span profiles comprise two wedge shaped shafts and two wedge shaped holes.
 21. The modular construction kit of claim 8, wherein a corner component is provided and has two faces each provided with connecting means.
 22. The modular construction kit of claim 21, wherein the faces extend at an angle of approximately 96° to each other.
 23. The component or a modular construction kit of claim 1, wherein the component is made of a plastic material.
 24. The modular construction kit of claim 8, wherein the plurality of components comprise the first component which consists of the substantially straight element.
 25. The modular construction kit of claim 8, wherein the plurality of components comprise the second component which is curved and subtends the first angle.
 26. The modular construction kit of claim 25, wherein the plurality of components comprise the third component which is curved and subtends the second angle which is approximately half of the first angle.
 27. The modular construction kit of claim 8, wherein the plurality of components comprise the fourth component which consists of the corner element.
 28. (canceled) 